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Headlight and Windshield Washer Pumps Replacement
 
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Pelican Technical Article:

Headlight and Windshield Washer Pumps Replacement

Steve Vernon

Time:

15 minutes to 1 hour

Tab:

$15 to $160

Talent:

**

Tools:

Flathead screwdriver

Applicable Models:

Porsche 944 Turbo (1986-89)

Parts Required:

Pumps

Hot Tip:

Use care, as the plastic gets brittle

Performance Gain:

Clean windshield and headlights

Complementary Modification:

New wiper blades

There are two pumps on the Porsche 951's windshield and headlight reservoir. One feeds fluid to the windshield washers, while the other one pumps fluid to the headlight washers. Both of these pumps will fail over time. The time to replace them is when they start to go bad not when you need them in inclement weather. The pumps are both easily accessible, but the windshield washer pump is easier. You should leave yourself more time when planning to change the headlight washer pump.

You will not need to raise or support the vehicle unless you run into a very stubborn headlight pump. You need to have the headlights in the raised position to replace the headlight pump. You may find that you need to remove the headlight motor to give you more room to work so please see our article on headlight motor replacement for additional assistance. Begin working with the headlights raised.

Windshield Pump- The reservoir is located in the front right corner of the engine bay.
Figure 1

Windshield Pump: The reservoir is located in the front right corner of the engine bay. The windshield pump (red arrow) is mounted on the top front of the reservoir and pulls the coolant from the cap (green arrow). The cap was missing on our project car. If it is missing on yours you should replace it right away. The cap seals the reservoir, prevents dirt and debris from getting in and also stops the fluid from spilling out. From the pump there is a line that runs up to the windshield nozzles (yellow arrow).

Windshield Pump- Remove the fluid lines from the pump (yellow arrow) using care, as the plastic nipples on the pump get very brittle over time and can break off in the lines (red arrow).
Figure 2

Windshield Pump: Remove the fluid lines from the pump (yellow arrow) using care, as the plastic nipples on the pump get very brittle over time and can break off in the lines (red arrow).

Windshield Pump- Disconnect the electrical connection (red arrow).
Figure 3

Windshield Pump: Disconnect the electrical connection (red arrow).

Windshield Pump- There is a plastic clip (red arrow) that helps hold the pump in place on the bracket and reservoir.
Figure 4

Windshield Pump: There is a plastic clip (red arrow) that helps hold the pump in place on the bracket and reservoir.

Windshield Pump- Slide the clip and piece between the clip and mount (red arrow) towards the center of the car.
Figure 5

Windshield Pump: Slide the clip and piece between the clip and mount (red arrow) towards the center of the car. This will allow you to slide the pump over until the plastic tabs on the reservoir can slip out from the holes in the mounting plate (yellow arrows).

Windshield Pump- With the clip slid over you can remove the pump from the mounting tabs on the reservoir (red arrows).
Figure 6

Windshield Pump: With the clip slid over you can remove the pump from the mounting tabs on the reservoir (red arrows). Installation is the reverse of removal.

Headlight Pump- The headlight pump (red arrow) is down in the lower section of the reservoir below the headlight motor (yellow arrow).
Figure 7

Headlight Pump: The headlight pump (red arrow) is down in the lower section of the reservoir below the headlight motor (yellow arrow). Depending on the size of your hands you may need to remove the headlight motor. At the very least you will need to unplug it and remove the relay to give you more room to work (yellow arrow). Begin by disconnecting the electrical connection (red arrow) for the pump. You are going to reach down and tilt the pump slightly to one side and pull the pump up and out from the reservoir. It just sits in a rubber grommet.

Headlight Pump- If the pump is really stuck you may need to get under the vehicle and help push the pump up with a flathead screwdriver (yellow arrow).
Figure 8

Headlight Pump: If the pump is really stuck you may need to get under the vehicle and help push the pump up with a flathead screwdriver (yellow arrow). While under the car you can make sure the fluid line is not stuck on anything (red arrow).

Headlight Pump- Pull the pump up and disconnect the fluid out of the line (red arrow) from the pump.
Figure 9

Headlight Pump: Pull the pump up and disconnect the fluid out of the line (red arrow) from the pump. Inspect to make sure the spigot end of the pump (yellow arrow) did not break off in the reservoir.

Headlight Pump- This photo illustrates the opening in the reservoir that the pump sits in (red arrow).
Figure 10

Headlight Pump: This photo illustrates the opening in the reservoir that the pump sits in (red arrow). You can see that I removed the headlight motor for more room (yellow arrow). Installation is the reverse of removal.








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